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QUALITY PDI COMPLAINT REGISTER

AMW
Sl.No Date of receipt Date of Complaint Logged Plant/Line Part Name / Part Number Probem Details

PDI Complaint Register


Received Qty (Nos) Problem faced QTY (Nos) Photo No. of time Occuranc e the same problem with same part every batch Effectiveness CAPA Responsibi Received lity on CAPA Status Ist Month 2 nd Month 3 rd Month Remarks

17/09/2010

17/09/2010

STYLE M-300 WCC047 WELDING

PROSITY

2160

215

ANIL MISHRA/ YOGESH

open

17/09/2010

17/09/2010

STYLE M-300 WCC047 WELDING

GRAINDING MARK

2160

100

ANIL MISHRA/ YOGESH

10/9/2010

10/9/2010

ASSY LINE-2

GMI-WCC023

SINGLE WELD MISSING

2016

ANIL MISHRA/ YOGESH

9/9/2010

9/9/2010

PRESS SHOP

ITL-WTF004

WRONG BOLT HOLE POSITION

469

HEMANT SINGH/ YOGESH

21/08/2010

21/08/2010

PRESS SHOP

MSIL WCC046

VENT HOLE DAMAGE

1400

HEMANT SINGH/ YOGESH

18/09/2010

18/09/2010

PAINT SHOP

MSIL WCC046

WRINKLES

830

500

BK THAKUR

10/9/2010

10/9/2010

RIM LINE

MSIL RCC023

TOOL MARK

1800

150

RAJKUMA R/YOGES H ANIL MISHRA/ YOGESH

15/09/2010

15/09/2010

ASSY LINE-2

M-200 WCC023 WITHOUT LPM DOT

456

45

15/09/2010

15/09/2010

PRESS SHOP

M-200 DCC012

DISC PITTED

350

25

HEMANT SINGH/ YOGESH

10

20/09/2010

20/09/2010

ASSY LINE-2

M-300 WCC047 WITHOUT LPM DOT

650

63

ANIL MISHRA/ YOGESH

11

20/09/2010

STYLE 20/09/2010 M-300 WCC047 WELDING

INTERMITENT WELDING

900

ANIL MISHRA/ YOGESH

12

20/09/2010

20/09/2010

ASSY LINE-2

M-200 WCC023

WITHOUT SPATTER CLEANING

450

250

ANIL MISHRA/ YOGESH

13

22/09/2010

22/09/2010

RIM LINE

M-200 WCC023

VALVE HOLE DAMAGE

845

ANIL MISHRA/ YOGESH

14

23/09/2010

23/09/2010

PAINT SHOP

M-200 WCC023

OIL DROPS

422

27

BK THAKUR

15

25/09/2010

25/09/2010

STYLE M-300 WCC047 ALL WELD MISSING WELDING

1350

48

ANIL MISHRA/ YOGESH

16

24/09/2010

24/09/2010

PAINT SHOP

M-300 WCC047

PAINT DROPS FROM BOTTON

850

45

BK THAKUR

17

1/9/2010

1/9/2010

ASSY LINE-2

M-200 WCC023

WELD SHIFT

1,460

100%

ANIL MISHRA/ YOGESH

18

1/9/2010

1/9/2010

RIM LINE

M-200 WCC023

TOOL MARK RIM

1,145

50%

RAJKUMA R/YOGES H

19

29/09/2010

29/09/2010

RIM LINE

FORCE MOTORS BUT WELD WCC040 THROUGH CRACK

1008

Baskaran, M./RAJKU MAR/YOG ESH ANIL MISHRA/ YOGESH

20

10/1/2010

10/1/2010

ASSY LINE-2

FORCE MOTORS SINGLE WELD MISS WCC040

1008

21

30/09/2010

30/09/2010

RIM LINE

M-200 WCC023

DOUBBLE VALVE HOLE

1440

RAJKUMA R/YOGES H HEMANT SINGH/ YOGESH

22

25/09/2010

25/09/2010

PRESS SHOP

WTF002

BOLT HOLE DAMAGE

131

23

24

25

Format No:- F/WR/QC/37

Month & Year of Release with Revision Level:-Sep'10/R0

Counter Measure For PDI Complaints


Problem Description: Porosity in WCC047 welding Cause: 1. Inspection of unpainted wheel is not effective

Corrective Actions: Detection can be done only by visual. 1. Associates at unpainted wheel inspection to be trained for requirements Yogesh Srinivasan

Preventive Actions: 1. Training to the associates on Wheel Defects Yogesh Srinivasan 2. Immediate Inspection after welding Machine operator 3. Incoming discs and Rim should be free from oil - Mr. Yogesh Srinivasan 4. Patrol Inspection - Mr. Alpesh & Mr. Karthikeyan

Counter Measure For PDI Complaints


Problem Description: Single Weld Missing in M200(WCC023) Cause: 1. Inspection of unpainted wheel is not effective

Corrective Actions: Detection can be done only by visual. 1. Associates at unpainted wheel inspection to be trained for requirements Yogesh Srinivasan

Preventive Actions: 1. Training to the associates on Wheel Defects Yogesh Srinivasan 2. Sensor for weld miss detection to be incorporated - Mr. Baskaran 3. Patrol inspection Mr. Alpesh & Mr. Karthikeyan

Counter Measure For PDI Complaints


Problem Description: Tool Mark in MSIL Rim RCC023 Cause: 1. Inspection of unpainted wheel is not effective

Corrective Actions: Detection can be done only by visual. 1. Associates at rim and unpainted wheel inspection to be trained for requirements Yogesh Srinivasan

Preventive Actions: 1. Training to the associates on rim Defects Yogesh Srinivasan 2. Associate at rim line to be taught on requirements - Mr. P. N. Bhatt & Mr. Rajkumar 3. Patrol inspection Mr. Alpesh & Mr. Karthikeyan

Counter Measure For PDI Complaints


Problem Description: M300 Deep Grinding Mark Cause: 1. Inspection of unpainted wheel is not effective

Corrective Actions: Detection can be done only by visual. 1. Associates at unpainted wheel inspection to be trained for requirements Yogesh Srinivasan

Preventive Actions: 1. Training to the associates on Wheel Defects Yogesh Srinivasan 2. Associate at rework to be taught on requirements - Mr. Anil Mishra 3. Patrol inspection Mr. Alpesh & Mr. Karthikeyan

Date : 21.09.2010 Concern / Problem / Area for improvement:

Initiated by : B.K.Thakur

To reduce the Paint overflow, blackness & paint dust defects in MSIL wheels from 3.6% to1.0 %. Current Situation: . Presently we are getting 1.0% paint defect.

ASIA MOTORWORKS LTD.

Corrective & Preventive Action Form


Format No. : F/WR/MR/009 Ret. Period : 3 Years

Correction Action: 1. Training given to all painters for manual spray painting after the auto reciprocator painting in manual booth.( WI W/WR/PP1/022) 2. Training given to operator for proper cleaning of wheels before painting. 3. Training given to painter for bore area cleaning & touch up painting before final inspection.(W/WR/PP1/51).

SIGN : DATE : Team members Leader : BKT, Mr. Vipul, Mr. Chintan, Mr. Kuldeep

Target Date :

31.10.2010

Actual Date :

Root cause : 1. Unskilled painter. 2. Line stoppage during the power failure & tea break.

SIGN : Attach sheets / Fish bone Diagram / Parts Analysis etc. if reqd. Correction Action : Sr. No. Action Training given to all painter 1 2 Stable painter (min. 6 no.)

DATE :21.09.2010

Responsibility BKT BKT

Date immediate 21.09.2010

FISH BONE - PAINT DEFECT ANALYSIS

enviroment

man

booth temp. booth balance

painter touch up

Paint Defect ( overflow, blackness & bore Dust) manual gun paint viscosity application process Setting cleaning

material

method

Reciprocator

DATE : 08.10.10

Corrective & Preventive Action Report - 8D


SHIFT : G

CORRECTIVE ACTIONS / LONG TERM ACTION (At t ach Phot ographs of act ions t aken) Identified Root Cause from WHY-WHY analysis Gutter pit crack Corrective Actions Planned / taken 100% parts will be checked NA Error - Proofing Responsibility V ikas Garg
Date of Im plem entation

Next lot

MONITORING EFFECTIVENESS OF CORRECTIVE ACTIONS (REVIEW) Sr Corrective Actions Taken 100% parts will be checked Target 05.10.10 Actual 05.10.10 Results of Action taken Date of Review Status

7A

REVIEW - DOCUMENTS / SYSTEMS (Attach copies of all revised documents)


# 1 QMS Document Control Plan 2 3 4 5 6 7 8 Process sheet Drawing / Process Flow Diagram PFMEA / DFMEA / PPAP Acceptance Standard PM Checklist Work Instruction/Calibration Plan Other (Specify) In-house Supplier No No No No No NA P if Yes No Responsibility Planned date Actual Date Status

7B

PREVENTION/LESSONS LEARNED (List ot her similar processes & product s wit h t he pot ent ial for t he same defect ) Sr 1 Processes / Products Inspection shall be carried out 100% Corrective Actions Error - Proofing Responsibility V ikrant Date of Imple

# 1 2 3 4 5 6

PROBLEM CLOSURE & SIGN-OFF PROBLEM PROGRESS SUMMARY Phase Start Date Actual Date Problem Definition Containment Action Root Cause analysis Corrective Action Solution Confirmation Closure 17.09.10 17.09.10 17.09.10 17.09.10 17.09.10 17.09.10 17.09.10 17.09.10

Completion 20.09.10 20.09.10 20.09.10 20.09.10

Closure Sign-off Team Member Function Vikas Garg Vikrant Mfg Quality

Sign-0ff

Total Time required for rejected product analysis in days

= PA GE 2OF2

(Det erminat ion of root cause, correct ive act ion & monit oring effect iveness of implement at ion) MANAGEMENT VERIFICATION & CLOSURE Sign Date Name Head MFG
Prepared By Vikas Garg FORM AT NO : F/W R/M R/007 M onth& Year Of Release with Revision level

QA & Materials

Prodn

PPC

Tool Eng.
Approved By

Other

M ay'08/R0

DATE : 08.10.2010

Corrective & Preventive Action Report - 8D


SHIFT : G

Part Name Part No Drg Ref Date


1

WHEEL WTK005 WTK005

Vehicle Model Chassis No Customer

17.09.2010

Feedback from

AMW PDI

Problem Awareness Problem Scope New Problem Severity Safety Regulatory Functional Existing Aesthetic Reliability Reopened Others PDI Field Com plaints Dom estic / Export Line
Wheel rim line no. 5

Problem Source

Yes

Yes

MFG Shop AMW Wheel Rim Supplier

WHEEL RIM

% defect 1%

Part Nos

% defect

PROBLEM DEFINITION (At t ach Phot ographic det ails of failure, At t ach T rend dat a, Paret o analy sis, Warrant y et c)
Butt wel d Cr ack

CONTAINMENT ACTION / SHORT TERM ACTION

Implementation Sr Actions Planned / taken


CONT A I NMENT : Exist ing lot w ill be checked for 100%
1 17.09.2010

Start Date

End Date
17.11.2010

Responsibility
AMW

Break Point

SHORT T ERM A CT I ON:Next lot w ill be t aken care by 100% inspect ion
2 Next lot AMW

ROOT CAUSE ANALYSIS

(At t ach Ishi kaw a di agram -Cause & Ef f ect ) WHY ~ WHY... ANALYSIS Root Cause Root Cause

Voltage Drop 1 WHY ?

Increase in load 2 WHY ?

3 WHY ?

4 WHY ?

5 WHY ?

Prepared By Prashant Varia FORM AT NO : F/W R/M R/007

Approved By

M onth& Year Of Release with Revision level

M ay'08/R0

DATE : 08.10.10

Corrective & Preventive Action Report - 8D


SHIFT : G

CORRECTIVE ACTIONS / LONG TERM ACTION (At t ach Phot ographs of act ions t aken) Identified Root Cause from WHY-WHY analysis Butt weld Crack Corrective Actions Planned / taken Capacitor bank put in operation NA Error - Proofing Responsibility A run Tidke
Date of Im plem entation

Next lot

MONITORING EFFECTIVENESS OF CORRECTIVE ACTIONS (REVIEW) Sr Corrective Actions Taken Capacitor bank put in operation Target 05.10.10 Actual 05.10.10 Results of Action taken Date of Review Status

7A

REVIEW - DOCUMENTS / SYSTEMS (Attach copies of all revised documents)


# 1 QMS Document Control Plan 2 3 4 5 6 7 8 Process sheet Drawing / Process Flow Diagram PFMEA / DFMEA / PPAP Acceptance Standard PM Checklist Work Instruction/Calibration Plan Other (Specify) In-house Supplier No No No No No NA P if Yes No Responsibility Planned date Actual Date Status

7B

PREVENTION/LESSONS LEARNED (List ot her similar processes & product s wit h t he pot ent ial for t he same defect ) Sr 1 Processes / Products Inspection shall be carried out 100% Corrective Actions Error - Proofing Responsibility V ikrant Date of Imple

# 1 2 3 4 5 6

PROBLEM CLOSURE & SIGN-OFF PROBLEM PROGRESS SUMMARY Phase Start Date Actual Date Problem Definition Containment Action Root Cause analysis Corrective Action Solution Confirmation Closure 17.09.10 17.09.10 17.09.10 05.10.10 17.09.10 17.09.10 17.09.10 05.10.10

Completion 20.09.10 20.09.10 20.09.10 05.10.10

Closure Sign-off Team Member Function Prasshant Varia Vikrant Arun Tidke Mfg Quality Electrical

Sign-0ff

Total Time required for rejected product analysis in days

= PA GE 2OF2

(Det erminat ion of root cause, correct ive act ion & monit oring effect iveness of implement at ion) MANAGEMENT VERIFICATION & CLOSURE Sign Date Name Head MFG
Prepared By Prashant Varia FORM AT NO : F/W R/M R/007 M onth& Year Of Release with Revision level

QA & Materials

Prodn

PPC

Tool Eng.
Approved By

Other

M ay'08/R0

DATE : 08.10.2010

Corrective & Preventive Action Report - 8D


SHIFT : G

Part Name Part No Drg Ref Date


1

WHEEL WTK005 WTK005

Vehicle Model Chassis No Customer

17.09.2010

Feedback from

AMW PDI

Problem Awareness Problem Scope New Problem Severity Safety Regulatory Functional Existing Aesthetic Reliability Reopened Others PDI Field Com plaints Dom estic / Export Line
Wheel rim line no. 5

Problem Source

Yes

Yes

MFG Shop AMW Wheel Rim Supplier

WHEEL RIM

% defect 1%

Part Nos

% defect

PROBLEM DEFINITION (At t ach Phot ographic det ails of failure, At t ach T rend dat a, Paret o analy sis, Warrant y et c)
Butt wel d deep pi tti ng mar k

CONTAINMENT ACTION / SHORT TERM ACTION

Implementation Sr Actions Planned / taken


CONT A I NMENT : Exist ing lot w ill be checked for 100%
1 17.09.2010

Start Date

End Date
17.11.2010

Responsibility
AMW

Break Point

SHORT T ERM A CT I ON:Next lot w ill be t aken care by 100% inspect ion
2 Next lot AMW

ROOT CAUSE ANALYSIS

(At t ach Ishi kaw a di agram -Cause & Ef f ect ) WHY ~ WHY... ANALYSIS Root Cause Root Cause

Flash cutting top Clam p blocks not ok 1 WHY ?

2 WHY ?

3 WHY ?

4 WHY ?

5 WHY ?

Prepared By Prashant Varia FORM AT NO : F/W R/M R/007

Approved By

M onth& Year Of Release with Revision level

M ay'08/R0

DATE : 08.10.10

Corrective & Preventive Action Report - 8D


SHIFT : G

CORRECTIVE ACTIONS / LONG TERM ACTION (At t ach Phot ographs of act ions t aken) Identified Root Cause from WHY-WHY analysis Butt weld deep pitting mark Corrective Actions Planned / taken Reconditioning done for the top clamping blocks NA Error - Proofing Responsibility Prashant v aria
Date of Im plem entation

Next lot

MONITORING EFFECTIVENESS OF CORRECTIVE ACTIONS (REVIEW) Sr Corrective Actions Taken Reconditioning done for the top clamping blocks Target 05.10.10 Actual 05.10.10 Results of Action taken Date of Review Status

7A

REVIEW - DOCUMENTS / SYSTEMS (Attach copies of all revised documents)


# 1 QMS Document Control Plan 2 3 4 5 6 7 8 Process sheet Drawing / Process Flow Diagram PFMEA / DFMEA / PPAP Acceptance Standard PM Checklist Work Instruction/Calibration Plan Other (Specify) In-house Supplier No No No No No NA P if Yes No Responsibility Planned date Actual Date Status

7B

PREVENTION/LESSONS LEARNED (List ot her similar processes & product s wit h t he pot ent ial for t he same defect ) Sr 1 Processes / Products Inspection shall be carried out 100% Corrective Actions Error - Proofing Responsibility V ikrant Date of Imple

# 1 2 3 4 5 6

PROBLEM CLOSURE & SIGN-OFF PROBLEM PROGRESS SUMMARY Phase Start Date Actual Date Problem Definition Containment Action Root Cause analysis Corrective Action Solution Confirmation Closure 17.09.10 17.09.10 17.09.10 17.09.10 17.09.10 17.09.10 17.09.10 17.09.10

Completion 20.09.10 20.09.10 20.09.10 20.09.10

Closure Sign-off Team Member Function Prasshant Varia Vikrant Mfg Quality

Sign-0ff

Total Time required for rejected product analysis in days

= PA GE 2OF2

(Det erminat ion of root cause, correct ive act ion & monit oring effect iveness of implement at ion) MANAGEMENT VERIFICATION & CLOSURE Sign Date Name Head MFG
Prepared By Prashant Varia FORM AT NO : F/W R/M R/007 M onth& Year Of Release with Revision level

QA & Materials

Prodn

PPC

Tool Eng.
Approved By

Other

M ay'08/R0

DATE : 08.10.2010

Corrective & Preventive Action Report - 8D


SHIFT : G

Part Name Part No Drg Ref Date


1

WTK004 WTK004

Vehicle Model Chassis No Customer

17.09.2010

Feedback from

AMW PDI

Problem Awareness Problem Scope New Problem Severity Safety Regulatory Functional Existing Aesthetic Reliability Reopened Others PDI Field Com plaints Dom estic / Export Line
Wheel rim line no. 4

Problem Source

Yes

Yes

MFG Shop AMW Wheel Rim Supplier

WHEEL RIM

% defect 1%

Part Nos

% defect

PROBLEM DEFINITION (At t ach Phot ographic det ails of failure, At t ach T rend dat a, Paret o analy sis, Warrant y et c)
T yr e seat ar ea bur r

CONTAINMENT ACTION / SHORT TERM ACTION

Implementation Sr Actions Planned / taken


CONT A I NMENT : Exist ing lot w ill be checked for 100%
1 17.09.2010

Start Date

End Date
17.11.2010

Responsibility
AMW

Break Point

SHORT T ERM A CT I ON:Next lot w ill be t aken care by 100% inspect ion
2 Next lot AMW

ROOT CAUSE ANALYSIS

(At t ach Ishi kaw a di agram -Cause & Ef f ect ) WHY ~ WHY... ANALYSIS Root Cause Root Cause

Jobs put in final roll form er without cleaning grinding dust. 1 WHY ?

2 WHY ?

3 WHY ?

4 WHY ?

5 WHY ?

Prepared By Vikas Garg FORM AT NO : F/W R/M R/007

Approved By

M onth& Year Of Release with Revision level

M ay'08/R0

DATE : 08.10.10

Corrective & Preventive Action Report - 8D


SHIFT : G

CORRECTIVE ACTIONS / LONG TERM ACTION (At t ach Phot ographs of act ions t aken) Identified Root Cause from WHY-WHY analysis Tyre seat area burr Corrective Actions Planned / taken Grinding dust will be cleaned before feeding jobs for final roll former. NA Error - Proofing Responsibility V ikas Garg
Date of Im plem entation

Next lot

MONITORING EFFECTIVENESS OF CORRECTIVE ACTIONS (REVIEW) Sr Corrective Actions Taken Grinding dust will be cleaned before feeding jobs for final roll former. Target 05.10.10 Actual 05.10.10 Results of Action taken Date of Review Status

7A

REVIEW - DOCUMENTS / SYSTEMS (Attach copies of all revised documents)


# 1 QMS Document Control Plan 2 3 4 5 6 7 8 Process sheet Drawing / Process Flow Diagram PFMEA / DFMEA / PPAP Acceptance Standard PM Checklist Work Instruction/Calibration Plan Other (Specify) In-house Supplier No No No No No NA P if Yes No Responsibility Planned date Actual Date Status

7B

PREVENTION/LESSONS LEARNED (List ot her similar processes & product s wit h t he pot ent ial for t he same defect ) Sr 1 Processes / Products Inspection shall be carried out 100% Corrective Actions Error - Proofing Responsibility V ikrant Date of Imple

# 1 2 3 4 5 6

PROBLEM CLOSURE & SIGN-OFF PROBLEM PROGRESS SUMMARY Phase Start Date Actual Date Problem Definition Containment Action Root Cause analysis Corrective Action Solution Confirmation Closure 17.09.10 17.09.10 17.09.10 05.10.10 17.09.10 17.09.10 17.09.10 05.10.10

Completion 20.09.10 20.09.10 20.09.10 05.10.10

Closure Sign-off Team Member Function Prasshant Varia Vikrant Mfg Quality

Sign-0ff

Total Time required for rejected product analysis in days

= PA GE 2OF2

(Det erminat ion of root cause, correct ive act ion & monit oring effect iveness of implement at ion) MANAGEMENT VERIFICATION & CLOSURE Sign Date

Name Head MFG


Prepared By Prashant Varia FORM AT NO : F/W R/M R/007 M onth& Year Of Release with Revision level M ay'08/R0

QA & Materials

Prodn

PPC

Tool Eng.
Approved By

Other

BOLT SHIFTED

45

BOLT SHIFTED

OVER PENETRATION

WELD PENETRATION IN RIM

45

G DISC ASSY(WTR024)

65

Counter Measure For PDI Complaints


Problem Description: Porosity in stiffner welding.3Nos Cause: 1.Oil found in disc 2.Inspection not carried out after stiffener welding however done at disc rework & after assembly

Corrective Actions: Detection can be done only by visual. 1. Associates at final inspection to be taught on requirements - Resp. Mr.ChetanPatel 2. Incoming disc quality to be improved - Resp Mr.Anandha Perumal

Preventive Actions: Immediate Inspection after stiffener welding. 1. Incoming discs for stiffner welding should be free from oil-Resp.Mr.Anantha Perumal 2. Machine operator to be taught on requirements - Resp. Mr.Aravindhan 3. Patrol Inspection - Resp Mr.Chetan Patel

Counter Measure For PDI Complaints


Problem Description: Rear Side Marking.1Nos Cause: 1.Wrong positioning / handling of rims at Rim Line

Corrective Actions: Detection can be done only by visual 1.Associates at rim line to be taught on requirements - Resp. Mr.Dilip 2.Associates at final inspection to be taught on requirements - Resp. Mr.ChetanPatel

Preventive Actions: Training to the operators on rim handling 1. Machine operator to be taught on requirements Resp.Mr.Dhanshuk 2. Patrol Inspection - Resp Mr.Chetan Patel

Counter Measure For PDI Complaints


Problem Description: Uneven Lug Weld & Over Penetration.2Nos Cause: 1.Process not stabilized

Corrective Actions: Detection can be done only by visual 1. Associates at lug welding to be taught on requirements - Resp. Mr.Dilip 2. Associates at final inspection to be taught on requirements - Resp. Mr.ChetanPatel

Preventive Actions: Standardizing welding parameters 1. Process Qualification - Resp Mr.Aravindhan

Counter Measure For PDI Complaints


Problem Description: Bolt Twist Problem. Cause: Fixtures worn out

Corrective Actions: Detection can be done only by visual. 1. Associates at final inspection to be taught on requirements - Resp. Mr.ChetanPatel

Preventive Actions: Mistake proofing fixtures 1. Fixtures to be reconditioned - Resp Mr.Tharun / Mr.Aravindhan